SixSigmaProjectGuideline

Technische Universitt Mnchen

Mean
StDev
Variance
Skewness
Kurtosis
N

Percent

Count

40

20

Fe

h le

be

i:

P re

is

C ou nt
P erce nt
C um %

le
eh

e
rb

Na

i:

en

h le
Fe
4 ,8 1
2 2,9
6 2,9

8 ,4 2
4 0,0
4 0,0

be

i:

Ka

r te

N
n-

le
eh

be

i:

CV

V -N

Fe

3,61
1 7 ,1
8 0 ,0

h le

be

i:

2,41
1 1 ,4
9 1 ,4

e
od

ab
cd

1,80
8 ,6
1 0 0 ,0

B o x pl o t o f S tim m u n g b y Z e it
4 ,0

-3

-2

-1

-0

GraphicalInspectionofData

0,02145
0,97241
0,94559
-0,124656
-0,003328
1000

Minimum
-3,57137
1st Quartile
-0,63316
Median
0,00431
3rd Quartile
0,65294
Maximum
2,67709
95% Confidence Interval for Mean
-0,03889
0,08179
95% Confidence Interval for Median
-0,04487
0,11464

3 ,5
3 ,0
2 ,5
2 ,0
1 ,5
1 ,0
1

2
Z e it

Process Capability Report for Yt1_Cookie-Weight

ProcessandOutput
Problem
Effect
Solutionideas ifpresent

Target

Comments

Evaluate the % of out-of-control points.

USL

0%

Overall
Within

Process Data
LSL
18
Target
20
USL
22
Sample Mean 20,9507
Sample N
60
StDev(Overall) 2,33315
StDev(Within) 2,04775

The process mean may not be stable. 5 (15,6%) data points are out of control
on the I chart. Keep in mind that you may see 0,7% out-of-control points by
chance, even when the process is stable.

> 5%

Yes

Overall Capability
Z.Bench 0,18
Z.LSL
1,26
Z.USL
0,45
Ppk
0,15
Cpm
0,26
Potential (Within) Capability
Z.Bench 0,31
Z.LSL
1,44
Z.USL
0,51
Cpk
0,17

No
15,6%

Individual and Moving Range Charts

Investigate any out-of-control points.

25

UCL=23,92

10

_
X=5,89

-5
LCL=-12,13
UCL=22,14

20

15,0 16,5 18,0 19,5 21,0 22,5 24,0 25,5

Performance
Observed Expected Overall
PPM < LSL 100000,00
102992,26
PPM > USL 266666,67
326450,62
PPM Total 366666,67
429442,89

a)ParetoDiagram
b)Histogram
c)Boxplot
d)TimeSeriesPlot

ProcessCapability/Control

I-MR Chart of Y_Consumption_per_Day

Summary Report
Is the process mean stable?

LSL

ProcessCapabilityProcessControl

Specifytopic

60
10

Individual Value

89%

collecttopics
checkriskandsuitability
prioritizeProjects
selectProject

80

15

Moving Range

fine

Suitabilityfor
SixSigma

Anderson-Darling Normality Test

A-Squared
0,22
P-Value
0,828

10 0

20

F e h le r t y p

Stimmung

Identifytopic

72%

Analyse

De

Summary Report for Y

P a r e to C ha r t o f F e hl e r ty p

Riskoftopic

10

Expected Within
74799,56
304179,60
378979,15

__
MR=6,78

LCL=0

10

N: 32

13

16

Mean: 5,8947

19

22

25

28

StDev(within): 6,0087

31

StDev(overall): 4,0946

Yield%/DPU/DPMO
Zbench (SigmaLevel))/cp/cpk
IMR/xbarR/xbarS/P/UChart
asbaselineoftheProcess

Control limits are estimated using the StDev(within).

SIPOC

Process

Output

Requirements and deviations

Severity of Problems of Outputs (Y)

Experts
Belt-Team
Management

negative Influences and Probability (xp))

2
5
7

Graphical Display

specifybusinessrelevance
focusoncriticalProblems
definescopeandtargets
buildateam

18

20

Y _Brigh tness_of_Cook ie

x_Baking_Time

SolutionIdeas
Cause
(x)

developSolutionstoeliminate,
adjustorcircumventthe
RootCausesx
prioritizeSolutions

Problem
(Y)

Solution

DesignofExperiments

identifynecessaryInputs
specifytherequirements
specifydeviationsfromreq.
evaluateprobabilityofdeviations

Y=f(x)

ActionList

Measure3

Measure4

Risk-Analysis

011011102200801
110114051978101
101501195801001
010100101010101
001110100110011

definetasksandworkpackages
decideonimplementation
setdeadlines
defineresponsibilities

automaticallyformulatedwith:
typeofHypothesis(diff./rel.)
relevanceofHypothesis(Risk)
appropriatestatisticaltest

CollectData
collectexistingdata
measureactualdata

Management(Sponsor,Account.) /Role:check,decide,supportProject
Belt(BlackBelt/GreenBelt)

/Role:leadProject

Experts

/Role:supportProject

R
P
N

...?

...?

...?

Severity of
the Effect

Countermeasures

How could the trigger of the Failure/ Problem, i.e.

their Root-Causes be eliminated

...?

sugar/ bacterial plaque

10

350

immediate brushing of teeth after check of

chocolate

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

...?

DataCollectionPlan

Hypothesis

Det ection of
the Probl em

...?
tooth loss

Probabili ty of
Cause

Which Influence triggers the Failure/ Problem?

Risk-Prior ityNumber

...?

R
P
N

Rating:
1= always 10= never

periodic dental prophylaxis

Let the Chef weigh 10 g of chocolate for her

special Chocolate Check

1.

potential Causes of the Failure/ Problem

Rating:
1= no 10= catast rophic

can cause caries

What is the Effect of the Failure/ Problem?

Probabili ty of
Cause

By which existing Controls could the Failure/

Problem be detected, before it occurs?

potential Effects of the Failures/ Problems

Rating:
1= never 10= always

Which Failures/ Problems can result from the

Measures?

new Risk-Analysis

Improvement
Severity of
the Effect

actual controls to detect the Failures/

Problems

Risk-Prior ityNumber

evaluateimpactstrengthofthe
negativeInfluencesofInputs(xi)
andProcessSteps(xp)onthe
ProblemsoftheOutputs(Y)

potential Failures/ Problems

Measure (What has to be done?)

Rating:
1= never 10= always

C&EMatrix

FMEA

70

minimizeRisksofmeasures

initiate
motivate

ImplementMeasures

qualify
inform

ProcessCapabilityProcessControl
Process Capability Report for Yt1_Cookie-Weight

I-MR Chart of Y_Consumption_per_Day

Summary Report
Is the process mean stable?

LSL

Target

Comments

Evaluate the % of out-of-control points.

USL
Overall
Within

Process Data
LSL
18
Target
20
USL
22
Sample Mean 20,9507
Sample N
60
StDev(Overall) 2,33315
StDev(Within) 2,04775

Overall Capability
Z.Bench 0,18
Z.LSL
1,26
Z.USL
0,45
Ppk
0,15
Cpm
0,26
Potential (Within) Capability
Z.Bench 0,31
Z.LSL
1,44
Z.USL
0,51
Cpk
0,17

0%

The process mean may not be stable. 5 (15,6%) data points are out of control
on the I chart. Keep in mind that you may see 0,7% out-of-control points by
chance, even when the process is stable.

> 5%

Yes

No
15,6%

Individual and Moving Range Charts

Investigate any out-of-control points.

25

UCL=23,92

10

_
X=5,89

-5
LCL=-12,13
UCL=22,14

20

15,0 16,5 18,0 19,5 21,0 22,5 24,0 25,5

Observed
PPM < LSL 100000,00
PPM > USL 266666,67
PPM Total 366666,67

Performance
Expected Overall
102992,26
326450,62
429442,89

10

Expected Within
74799,56
304179,60
378979,15

__
MR=6,78

LCL=0

10

N: 32

13

16

Mean: 5,8947

19

22

25

28

StDev(within): 6,0087

31

StDev(overall): 4,0946

ProcessCapability/Control
Yield%/DPU/DPMO
Zbench (SigmaLevel)/cp/cpk
IMR/xbarR/xbarS/P/UChart
forimprovedProcess

Control limits are estimated using the StDev(within).

DifferenceRelationship
Boxplot of Y_Cookie_Weight

TestHypothesis

Scatterplot of Y_Brightness_of_Cookie vs x_Baking_Time

27,5

22
20

25,0

Y_C ookie_W eight

checkstability,linearity,repeat
abilityandreproducibilityofthe
measurementsystem
GageR&R

ProjectTeam:

optimizeparameterofSolutions
withDesignofExperiments(DOE)

Measure8

mapProcessStepsintoActivities
assignInputsandOutputs
specifyMethods&Resources
specifyInfluencesandtheirprob.

MeasurementSystemAnalysis

16

identifyRootCausesx
ofthenegativeinfluencesx

ntrol

Test: ANOVA

14

FaultTreeAnalysis

Co

There is a/ no Difference
in the degree of: (Y)
between: Levels of (x)

12

time_of_measurement

operationalizeInfluences(xi;xp)
andProblems(Y)
derivemeasurands andunits
determinescalelevel

12

10

Rating:
1= no 10= catast rophic

1
4

Operationalisation

Xin
Xp1
Xp2
Xpn

t_2

Individual Value

Yn

Y2
Yn

ProcessSteps
(Xp)

12
10

t_1

Moving Range

Y3

Y1

Xi1
Xi2

14

15,0

Y_Brightn ess_of_C ookie

Y2
3

Xi2

Input
(Xi)

DifferenceHypothesis:Ya =Yb
RelationshipHypothesis:Y=f(x)

16

FMEA
(Failure Mode and Effects Analysis)

Problems (Y)

Risk: 14%

easure

Input, Output, Methods & Resources

Problems
(Y)

17,5

ProcessMapping&Analysis

Process-Steps > Activities

Process-Steps
Xp2
(Xp)
Xpn

20,0

Det ection of
the Probl em

negative Influences and Probability (xi)

Xin
Xp1

22,5

18

InputAnalysis

Requirements and deviations

Xi1

20

interviewCustomer/Manager
deriverequirementsforOutputs
specifydeviationsofOutputs
evaluateseverityofdeviations

Input

Input
(Xi)

TestHypothesis

Scatterplot of Y_Brightness_of_Cookie vs x_Baking_Time

22

25,0

Improve

Scope/
Target

Y1

ProjectCharter

Project-Charter
Problem

Boxplot of Y_Cookie_Weight
27,5

VoC/VoB>CCR/CBR>CtQ

Voice of Customer & Business

Business
Relevance

DifferenceRelationship

structureProcessintomainthe
mainprocesssteps
assignInputsand
(intermediate)Outputs
assignSupplierandCustomer

Rating:
1= always 10= never

Input

Output

Y_C ookie_W eight

Process

Measure-No.

Input

22,5

20,0

17,5

18

DifferenceHypothesis:Yt1=Yt2
RelationshipHypothesis:Y=f(x)

16
14
12
10

15,0
t_1

t_2

10

time_of_measurement

12

14

16

18

20

x_Baking_Time

Plan Process
Monitoring and Out
of Control Measures

Document
Project and present
Results

Continue checking
Target Achievement

Define Standards
for the new Process

Start Continuous
Improvement

Continue checking
Process Capability

Tools:

sigmaGuide
Minitab

HandoverandcloseProject
StoryboardofProject
ProcessManagementPlan

Copyright:

reiner.hutwelker@softLogik.de